Combustion air proving apparatus with burner cut-off capability and method of performing the same

Abstract

A combustion air proving (CAP) system for a burner assembly having a burner for providing heated air to a location, a controller, and a back plate, where outside air is fed to the burner via a conduit. The CAP system is connected to an inlet of the system. An outlet of the system is connected to the burner via the back plate. A damper within the system is translatable between open and closed positions for allowing and blocking air flow, respectively. A sensor measures an air flow parameter of air flow to the burner. The sensor communicates with the controller, which shuts down the burner if the parameter measured by the sensor meets a predetermined threshold value. An assembly installer may test for proper sensor and controller functions by translating the damper to the closed position and blocking outside air flow.

The invention claimed is: 
     
       1. An apparatus for heating a location, comprising:
 a heating system and a controller, said system providing heat to said location, and said controller monitoring said system and having the capability to shut the system down; 
 an air supply conduit for feeding outside air to said system, said air supply conduit including a damper interchangeable between an open position and a closed position, said open position allowing said outside air to flow through said air supply conduit to said heating system, and said closed position preventing or impeding air from flowing through said air supply conduit to said heating system; 
 a sensor adjacent said damper and said heating system, said sensor in electrical communication with said controller, said sensor measuring a parameter correlating to, or representative of, air flow of said outside air to said system, and communicating said parameter to said controller, wherein said controller monitors said parameter and is responsive to a change in parameter, such that a predetermined threshold initiates a shutdown sequence of said system; 
 wherein said controller is programmed to determine whether a predetermined threshold value is met, said predetermined threshold value including a measurement of negative pressure, vacuum, air flow volume, or temperature within the heating system, as measured by the sensor. 
 
     
     
       2. The apparatus of  claim 1  wherein the sensor is a pressure sensor and the parameter is representative of a pressure level, such that a predetermined pressure level threshold signaled by said pressure sensor initiates the shutdown sequence of said system. 
     
     
       3. The apparatus of  claim 1  wherein the sensor is installed on or within said air supply conduit. 
     
     
       4. The apparatus of  claim 1  further including an air flow conduit or body attachable to said air supply conduit, said body an inlet and an outlet for the passage of said outside air flow, said damper disposed within said combustion air proving system body. 
     
     
       5. The apparatus of  claim 4  wherein said damper is in the form of a movable, rotatable disc, an iris valve, a pneumatic air valve, or flow control valve. 
     
     
       6. The apparatus of  claim 1  wherein the sensor is an air volume sensor or air temperature sensor. 
     
     
       7. The apparatus of  claim 1  wherein said heating system is a burner. 
     
     
       8. The apparatus of  claim 1  wherein said controller detects a predetermined pressure drop, a near-vacuum condition, or a decrease in combustion air volume, in said system, indicating a lack of air flow to said system. 
     
     
       9. A combustion air proving system for monitoring combustion air supplied to a burner, comprising:
 a body for the passage of air flow, said body having an inlet, an outlet, and a damper therebetween; 
 the damper for affecting the air flow monitored by a sensor, the damper further interchangeable between an open position and a closed position, the open position allowing air to flow through said body, and the closed position preventing or impeding air from flowing through said body; 
 said sensor disposed on said combustion air proving system body adjacent the damper and the body outlet, the sensor monitoring a parameter correlating to, or representative of, said air flow, wherein said sensor is an air pressure sensor or an air flow sensor, and said parameter is an air pressure level or an air flow level, respectively; 
 a biasing member for maintaining the damper in the open position, wherein said biasing member is selected from the group consisting of: a weight disposed on an edge of the damper, a magnet disposed within said body actively pushing on the damper, a spring exerting a constant force on the damper in a direction towards the open position, and a latch within said body for receiving and locking said damper in place. 
 
     
     
       10. The combustion air proving system of  claim 9  wherein said damper is a planar, rotatable structure within said body, or an iris valve within said body. 
     
     
       11. The combustion air proving system of  claim 10  wherein said damper in the form of said planar, rotatable structure is further connected to a pivot rod disposed within said body, said damper being rotatable about the pivot rod between said open position and said closed position. 
     
     
       12. The combustion air proving system of  claim 11  further including said damper lever attached to an end of said pivot rod for rotating said damper about said pivot rod between said open position and said closed position. 
     
     
       13. The combustion air proving system of  claim 12  further including a latching detent disposed on said body, and a lever detent disposed on said lever, said latching detent and said lever detent interactive with each other to lock the damper in place once fully rotated to said open position or said closed position. 
     
     
       14. The combustion air proving system of  claim 13  further including a travel stop disposed within said body for preventing over-rotation of said damper within said body between said open position and said closed position. 
     
     
       15. A method of operating a heating system, comprising:
 providing a controller to said heating system, said system providing heat to a location, said controller monitoring said heating system and having the capability to shut the heating system down; 
 said heating system including:
 an air supply conduit for feeding outside air to said system, said air supply conduit including a damper interchangeable between an open position and a closed position; and 
 a sensor in electrical communication with said controller, said sensor measuring a parameter correlating to, or representative of, air flow immediately egressing the damper, and communicating said parameter to said controller, wherein said controller monitors said parameter and is responsive to a change in parameter, such that a predetermined threshold initiates a shutdown sequence of said system; 
 
 firing said heating system; 
 measuring via said sensor a parameter correlating to, or representative of, an air flowing to the heating system; 
 sending a signal via the sensor responsive to said parameter measurement to said controller; 
 determining whether a predetermined threshold value is met, said predetermined threshold value including a measurement of negative pressure, vacuum, air flow volume, or temperature within the heating system, as measured by the sensor; and 
 shutting down the heating system via the controller when a signal from the sensor is determined by the controller to have reached a threshold value indicating a damper position preventing or impeding air from flowing through said air supply conduit to said heating system. 
 
     
     
       16. The method of  claim 15  further providing an air supply conduit, and further including the step of directing the air from a location away from said heating system into said heating system via said air supply conduit. 
     
     
       17. The method of  claim 16  further including measuring said parameter within said air supply conduit. 
     
     
       18. The method of  claim 15  further including:
 testing for air flow and sensor operation by preventing or impeding air flow and monitoring said parameter during said testing for air flow and sensor operation. 
 
     
     
       19. The method of  claim 15  further including:
 starting up the heating system via said controller after shutting down; 
 measuring said parameter; 
 determining whether said threshold value is still present; and 
 shutting down the heating system via the controller if said threshold value is still present. 
 
     
     
       20. The method of  claim 19  further comprising:
 performing three recycling start up attempts, including: 
 repeating starting up said heating system at least three additional times after shutting down said heating system for the first time; 
 determining whether said threshold value is still present throughout all at least three recycling start up attempts; 
 shutting down the heating system via said controller if the threshold value is present; and
 locking out said heating system via the controller if said threshold value is present after all three recycling start up attempts.